Process for mechanically treating materials having a movable flexible retarder

ABSTRACT

The flexible retarder is of a higher coefficient of friction than the primary surface and is mounted to be moved relative to the driving roll to avoid excessive wear. The retarder can be an endless belt, jacketed roller or an elongated strip and can be moved continuously or intermittently to expose fresh surfaces to the material being compacted.

United States Patent Trifunovic et al. [4 Aug. 8, 1972 [54] PROESS FORMECHANICALLY 2,263,712 1 l/ 1941 Wrighey et al. ..26/ l 8.6 TREATINGMATERIALS HAVING A 3,058,167 10/1962 Rainard et a]. ..28/ 1.6 MOVABLEFLEXIBLE RETARDER 3,260,778 7/ 1966 Walton ..26/ 18.6 UX [72] Inventors:Alexander L. Trifunovic, Wilming- $325 et ggzgg mi Newark 3,452,4097/1969 Trifunovic et a1. ..26/l 8.6 [73] Assignee: Joseph Bancroft 8:Sons Cm, Primary Examiner-Robert R. Mackey wllmmgton, Attorney-Kenyon &Kenyon Reilly Carr & Chapin [22] Filed: April 19, 1971 [211 Appl. No.:135,109 57 ABSTRACT m Application Data The flexible retarder is of ahigher coefficient of frict1on than the pnmary surface and 15 mounted tobe [62] Dmsmn M 793304, 241 9691 moved relative to the driving roll toavoid excessive 3,597,814- wear. The retarder can be an endless belt,jacketed roller or an elongated strip and can be moved continu- 52 US.(:1 ..26/18.6, l62/l 11 ously or intermittently to expose fresh surfacesto the [51 Ilrt. Cl ..D06c 21/00 material being compacted [58] Fleld ofSearch ..26/l8.6; 28/15, 72.14;

[56] References Cited 6 Claims, 9 Drawing Figures UNITED STATES PATENTS609,166 8/1898 Richardson ..26/l5 R 1 PATENTEDAus 8 I972 SHEET 2 BF 4wmawm ma 3 4 Ma m my Mechanical compression of materials such astextiles, paper, films and the like which are capable of beingmechanically compressed to a fractional proportion of original lengthhas been known, for example, as described in U.S. Pat. application Ser.No. 525,039,

filed Feb. 4, 1966 and now U.S. Pat. No. 3,452,409

granted July 1, 1969. The machines which have been utilized tomechanically compress materials in the manner suggested above haveusually relied on a first surface to confine the material to apredetermined thickness relative to a driving surface on theoppositeside of the first surface as well as a second surface opposite thedriving surface to define a cavity which decreases in the direction ofmovement of the material from the first surface and in which thematerial is compressed. In many instances, this second surface has beenformed of a wearable material such as rubber. However, it has been foundthat the wearable second surfaces, especially when made of rubber, tendto wear out rapidly and require a change, for example, after each 50 to100 yards of material is processed.

Because of the need to change the wearable second surfaces of thesemachines at such frequent intervals, these machines have not beencapable of extended efficient use. Further, these machines have requireda relatively long period of down-time in order to permit replacement ofthe wearable second surfaces.

Accordingly, it is an object of the invention to increase theoperational time of mechanical compressing machines.

It is another object of the invention to reduce the down-time forreplacing wearable friction surfaces in mechanical compressing machines.

Briefly, the invention provides a movable friction surface for amechanical material compressing machine which utilizes a drivingsurface, a primary surface, and a flexible retarder to define a cavityin which the material is compressed. The driving surface in suchmachines functions as a driving means for driving the material throughthe compression cavity. The primary surface serves to confine thematerial to a predetermined thickness before entry into the compressioncavity and the flexible retarder serves to slow the movement of thematerial in passing through the cavity relative to the speed at whichthe material enters the cavity.

The flexible retarder, according to the invention, is mounted in amanner to be moved relative to the primary surface so as to presentdifferent wear surfaces thereof to the cavity area. In one embodiment,the flexible retarder is formed as an elongated strip and is mounted tobe moved either in the direction of moveso as to be movedperpendicularly to the direction 'of movement of the material beingprocessed.

In still another embodiment, the flexible retarder is constructed as anendless belt and is mounted so as to be moved parallel to the directionof movement of the material being processed. Further, in thisembodiment, the flexible retarder is mounted on a frame which permitsthe flexible retarder to be adjusted horizontally and vertically withrespect to the primary surface and driving surface.

In still another embodiment, the flexible retarder is constructed incylindrical form as the peripheral surface of a roller and is mounted torotate in a direction with or against the direction of movement of thematerial being processed.

In all of the above embodiments of the invention, the flexible retarderis moved with respect to the characteristics of the processed materialwhich influence wear or the flexible retarder surface within thecompression cavity. For example, the flexible retarder is moved withrespect to such material characteristics as the type of the material,thickness, fiber content, weave, and the like. The amount and time ofmovement are such that a fresh surface of the flexible retarder ispresented to the processed material within the compression cavity beforethe prior flexible retarder becomes worn to a degree which inhibitsefficient and adequate processing of the material. In this way, thematerial can be processed substantially continuously withoutinterruption on account of wear in the flexible retarder. Further, themovement of the flexible retarder can be effected in a continuous orinterrupted manner. Where the movement is continuous, the flexibleretarder is synchronized with the processing speed of the material, forexample, at a speed reduction at 50 to 1, so as to be directly dependenton the movement of the processed material. Where the movement isinterrupted, the flexible retarder can be initiated manually orautomatically. For instance, after a predetermined length of materialhas been processed, as determined by a counting or measuring mechanism,a suitable transmission system can be activated to cause the flexibleretarder to move an increment of length and then stop. Similarly, atiming mechanism can be used to indicate when a certain length ofmaterial has been processed, for example, by lighting or sounding asignal, so that the flexible retarder can be moved manually orsemi-automatically.

By moving the flexible retarder relative to the processed material, thedown-time which would otherwise be required for replacement of a wornsurface is reduced considerably. Further, once an adjustment has beenmade for the flexible retarder relative to the compression cavity,succeeding sections of the flexible retarder surface exposed within thecompression cavity can be moved within the compression cavity withlittle or no further adjustment. Thus, the processing of a material ormaterials can be carried out in a rapid efficient manner.

These and other objects and advantages of the invention will become moreapparent from the following detailed description and appended claimstaken in conment of the material being processed or the oppositejunction with the accompanying drawings in which:

direction.

In another embodiment, the flexible retarder IS mounted in strip formtransversely across the material FIG. 1 illustrates a schematic view ofa machine for mechanically treating materials having a movable flexibleretarder according to the invention;

FIG. 2 illustrates a fragmentary perspective view of the flexibleretarder of FIG. 1;

FIG. 3 illustrates a view taken on line 3-3 of FIG. 2 showing therelationship of the movable flexible retarder relative to thecompression cavity;

FIG. 4 illustrates a fragmentary perspective view of a modified flexibleretarder according to the invention;

FIG. 5 illustrates a view taken on line 5-5 of FIG. 4;

FIG. 6 illustrates a side view of another modified flexible retarder ofthe invention in endless form;

FIG. 7 illustrates an enlarged detail of FIG. 6 taken through thecompression cavity;

FIG. 8 illustrates another modified flexible retarder of the inventionin endless form; and

FIG. 9 illustrates an enlarged detail of FIG. 8 taken through thecompression cavity.

Referring to FIGS. 1 and 2, a machine 10 for mechanically compressingmaterials, for example, a web 11 of textile material, includes a driveroller 12 of knurled surface for driving the web 11, a shoe apparatus 13containing a primary surface 14in the form of a resilient plate forconfining the web 1 1 against the roller 12 and a movable flexibleretarder 15 in the form of a strip for retarding the forward motion ofthe web 11. The web 11 is delivered onto the knurled surface of thedrive roller 12 in flattened form from a supply roll 16 positioned belowthe drive roller 12, as shown, or spaced horizontally from the driverroller 12 (not shown). In addition, the web 11, after processing, istaken up by a take-up system 17 located outside the machine 10 over aseries of guide rollers 18 as is known.

Referring to FIG. 2, the shoe apparatus 13 is pivotally mounted on afixed frame 19 of the machine 10 over the drive roller 12 and is pressedtowards the drive roller 12 under the influence of a pneumatic orhydraulic press 20 also mounted on the frame 19. The press 20 which caninclude a plurality of spaced rams 21 abuts on the top of the shoeapparatus 13 so as to prevent upward movement of the shoe apparatusabove a predetermined spacing from the drive roller 12. The

rams 21 are adjustable with respect to the shoe apparatus 13 so as topermit the spacing of the shoe an paratus 13 from the drive roller 12 tobe varied.

The shoe apparatus 13 is freely pivoted on suitable links 22 at the endsof the frame 19 to rest on the drive roller 12 and mounts the primarysurface 14 in the form of a flexible steel plate a the bottom. Theprimary surface plate is mounted in a cantilever manner to extend overthe drive roller 12. Additionally, the shoe apparatus 13 is slotted atthe rear to permit passage of the flexible retarder 15. The flexibleretarder 15 is disposed in a plane above the primary surface plate andextends past the free edge 23 of the primary surface 14. A pair of rigidpressure plates 24 are secured in the shoe apparatus 13 on an inclinedplane and press against the flexible retarder l5 and primary surface 14to ensure a pressure contact between the web 11 and these parts. Inorder to facilitate the positioning of the flexible retarder 15 and toavoid sharp comers, a back-up blade 25 is secured, as by recessed screwsor by welding, to the underside of the plates 24 and extends out fromthe plates 24 over the flexible retarder 15.

The flexible retarder 15 is in the form of a strip or belt and is of africtional material such as rubber having a Durometer of about 50 and acoefficient of friction higher than the primary surface 14. The strip ismounted on and between a pair of rollers 26, 27 so as to be wound andunwound from the respective rollers to transverse a path passing throughthe shoe apparatus 13.

Referring to FIG. 3, the drive roller 12, primary surface 14 andflexible retarder l5 define a compression cavity C in which the web 11is longitudinally compressed. The cavity C begins at and extends fromthe free edge 23 of the primary surface 14 forwardly between the driveroller 12 and flexible retarder 15 at a decreasing rate of height. Thecavity C at the edge 23 of the primary surface 14 is of greater heightthan the space between the primary surface 14 and drive roller 12 sothat the web 11 which is slowed in passing between the drive roller 12and flexible retarder 15 can begin to longitudinally compressimmediately upon entry into the cavity C. Depending on the rate of wearon the flexible retarder 15 within the cavity C, the flexi-.

ble retarder 15 is moved relative to the cavity C to present freshsurfaces to the cavity C.

The movement of the flexible retarder 15 is accomplished in anintermittent manner so as to move in increments equal to the length ofthe flexible retarder surface within the cavity C. Alternatively, theflexible retarder 15 can be moved continuously at a rate relative to thespeed of the travelling web 1 1. For example, where the flexibleretarder surface would wear out after exposure to about 100 yards ofweb, the flexible retarder 15 is moved at a rate to present 'a freshsurface within the cavity after passage of about to yards of web. Thiswill further ensure against any wearing out of the flexible retardersurface which might cause imperfections in the compressed web.

The movement of the flexible retarder 15 is accomplished by rotating therollers 26, 27 so that as the retarder 15 unwinds from one roller italso winds up on the other roller. In order to rotate the rollers 26,27, a suitable manually operated handle (not shown) is connected to oneroller to allow manual rotation of the roller. In this case, the otherroller can be freely mounted so as to rotate under the pulling force ofthe retarder 15. Also, this latter roller can be suitably braked so asto avoid an excessive rate of unwinding of the flexible retarder 15.

Alternatively, the roller 26, 27 can be connected mechanically to thedrive (not shown) of the drive roller 12 via a suitable transmission.That is, the drive of the drive roller 12 which is connected thereto byan endlessbelt arrangement 28 also drives at least one of the roller 26,27 at a reduced rate with respect to the drive roller 12. In order toallow intermittent movement of the flexible retarder, a clutch mechanismis interconnected in the drive so as to selectively engage and disengagethe drive to and from the rollers 26, 22

Referring to FIG. 4, wherein like numerals indicate like parts as above,the flexible retarder 15 is mounted transversely of the drive roller 12.As above, the flexible retarder 15 is in strip form and is positioned topass between the primary surface 14 and the back-up blade 25 of the shoeapparatus 13. The flexible retarder strip is of a width to extend from apoint between the primary surface 14 and show apparatus 13 past the freeedge 23 of the primary surface 14 to a point sufficient to permitformation of the compression cavity C as above described. Additionally,the shoe apparatus 13 is under sufficient pressure to clamp the flexibleretarder 15 between the back-up blade and primary surface 14 to preventa pull out of the flexible retarder in the direction of travel of theweb 11 under the forces generated by the web 1 1. However, the clampingforces on the flexible retarder 15 are such as to permit longitudinalsliding of the flexible retarder 15 so as to facilitate a change in thesurface of the flexible retarder presented to the compression cavity C.Alternatively, the flexible retarder 15 can also be clamped against suchlongitudinal sliding. In this alternative case, the pressure exerted bythe shoe apparatus 13 on the flexible retarder 15 is periodicallyrelieved so as to permit longitudinal displacement of the flexibleretarder strip.

Referring again to FIG. 4, the strip of flexible retarder 15 is mountedon'a pair of rollers 29 of the flanged-type to be wound and unwoundthereon as above. The rollers 29, 30 are rotatably mounted and arerotated either by manual or mechanical controls as described above.Further, the longitudinal displacement of the flexible retarder 15 iscarried out, as above, either in increments or continuously.Accordingly, since the movement and controls for movement of theflexible retarder 15 are similar to those described above, furtherdescription of such is not believed to be necessary hereat.

Referring to FIGS. 6 an 7, an alternate machine 30 for mechanicallycompressing a web 31 of material includes a drive roller 32, a primarysurface 33 and an endless flexible retarder 34. The drive roller 32 isconstructed as above with a knurled surface 35 for initially receivingthe web 31 and for driving the received web through the compressioncavity C (FIG. 7) formed between the drive roller 32 on one side and theprimary surface edge 36 and flexible retarder 34 on the other side. Theprimary surface 33 is formed of a resilient plate such as a stainlesssteel plate which is cantilevered over the drive roller 32 from theframe '37 of the machine 30. The flexible retarder 34 is formed of aresilient endless belt which passes under the lower point of the surfaceof a pressing roller 38, for example, of steel. The roller 38 isslidably mounted at opposite ends via stub shafts 39 in a guideway 40for vertical displacement. In addition, a second roller 41 of greaterweight and diameter than the roller 38 is likewise slidably mounted viastub shafts 42 in the guideway 40 so as to place a weighted load on theroller 38 and consequently on the flexible retarder 34 withincompression cavity C (FIG. 7). The latter roller 41 is replaceable sothat different loads can be imposed on the flexible retarder 34. Thediameter of the pressing roller 38 is such as to concentrate the weightpressing down on the flexible retarder strip within the limited area ofthe compression cavity C.

The guideway 40 which freely mounts the rollers 38, 41 is mounted in theframe 37 so as to be slidable in a horizontal plane. For example, theguideway 40 is secured to the top of the frame 37, as by a screw 45,passing through a suitably slotted opening in the guideway. In addition,the guideway 40 is supported by a pair of arms 44 which are mounted onopposite ends of the guideway 40 and which are secured, as by a screw 46passing through a suitably slotted opening in each arm 44, to the frame37. The rollers 42 are journalled in support members 47 which aremounted on the top of the guideway frame 40 so as to move therewith.Thus, depending on the material make-up of the web 31 being processed,the size of the compres sion cavity C can be varied by moving theguideway 40 horizontally as well as by changing the weights of therollers 38, 41 or the size of the roller 38.

The endless belt flexible retarder 34 is also mounted to pass over apair of rotatably mounted rollers 42 suitably joumalled in the machine30 so as to form a triangular shaped path. At least one of the rollers38, 42 is driven so as to intermittently or continuously cause theendless belt retarder 34 to move in a direction with or against thedirection of movement of the travelling web 31 In this regard, the drivefor these rollers 38, 42 is taken off the main drive of the machine 30in a manner similar to that above described.

Referring to FIGS. 8 and 9, a further alternate machine 50 formechanically compressing a web 51 of material as above includes a driveroller 52, a primary surface 53 and an endless flexible retarder 54. Thedrive roller is constructed as above with a knurled surface as above fordriving the received web 51 through the compression cavity C (FIG. 9).The primary surface 53 is mounted in cantilevered fashion from a frame55 of the machine 50 so as to confine the web 51 to a predeterminedthickness, for example, in the case of textile fabrics to a thicknessslightly less than the normal thickness of the web immediately prior toentry into the compression cavity C and in the case of paper,

to the free thickness of the paper. As above, the primary surface 53 isformed by a resilient plate such as a stainless steel plate. Theflexible retarder 54 is formed as a flexible coating, sleeve or stripover the surface of a roller 56 of non-resilient material such as steel.The roller 56 is driven, for example from the main drive of the machine50 either intermittently or continuously to cause the flexible retarder54 to move in the direction of or opposite to the travelling web 51. Theroller 56 is further mounted in a manner which directs a constant forceduring operation downwardly against the primary surface 53 towards thedrive roller 52. This force can be developed by mounting the ends of theroller 56 in an adjustable yoke arrangement (not shown) or by springmounting the ends of the roller 56.

In operation, the roller 56 is synchronized with the movement of thedrive roller 52 so that in the case of continuous motion the roller 56rotates at a predetermined relative speed with respect to the driveroller 52. In the event of an intermittent motion the roller 56 isintermittently driven in an increment sufficient to present a freshsurface of the flexible retarder 54 within the compression cavity C. Asshown, the compression cavity extends from the free edge 57 of theprimary surface 53 across the respective surfaces of the flexibleretarder 54 and drive roller 52 in a decreasing manner.

It is noted that the compression cavity C in all of above describedembodiments, assumes a configuration such that at the entry, the cavityis of its largest height and thereafter decreases to the end.Additionally, the passage leading to the compression cavity C is of lessheight than the entrance of the cavity. Consequently, the web which isbeing processed initially enters the cavity C at a predeterminedthickness,

material is slowed in travel in passing through the cavity due to theincrease in friction and corresponding drag forces on the web from theflexible retarder.

It is further noted that in those embodiments above where the flexibleretarder moves across the edges of the primary surface that the comersof the respective primary surfaces can be slightly rounded so as toavoid scoring of the flexible retarder surface during relative movement.It is also noted that in order to avoid any scoring of the flexibleretarder by the comers of the primary surfaces that the flexibleretarders can be moved in incremental fashion after the pressure betweenthe flexible retarders and primary surfaces is relieved.

The invention thus provides a means of processing a large quantity ofmaterial before replacement of the flexible retarder is necessary.Because of this, the down-time of the machinery is considerably reducedso that a much more efficient operation can be carried out thanotherwise possible.

The invention also provides a system wherein the flexible retarder canbe manipulated to present fresh unwom surfaces to the compression cavityof the machine without reliance upon extra ordinary skill on the part ofthe machine operators. Furthermore, the system can be fully automated sothat continuous operation can be carried out.

What is claimed is:

1. In a process for mechanically compacting a material of predeterminedthickness including the steps of driving a length of the material via adriving means while confining the material to maintain the predeterminedthickness and substantially undistorted state of the material,thereafter driving the length of material via said driving means into anaccumulation cavity having an inlet of a predetermined clearance greaterthan the predetermined thickness of the material and an outlet of apredetermined clearance less than the predeter mined clearance of theinlet, and frictionally engaging the material being advanced through theaccumulation cavity on one side of the material with a surface of aflexible retarder throughout the accumulation cavity to impose afriction force thereon in a direction substantially opposite to thedirection in which the material is advanced for slowing the forwardmovement of the material while simultaneously supporting the material onthe opposite side on the driving means throughout the accumulationcavity to increase the thickness of the material upon being advancedinto the cavity and to accumulate and compress the materiallongitudinally within the cavity as the material is advanced through thecavity; the step of moving the flexible retarder rela tive to thedriving means at a speed less than the speed of the driving means topresent fresh surfaces of said flexible retarder to the conveyed webduring mechanical compaction of the web.

2. In a process as set forth in claim 1 wherein the flexible retarder ismoved through an endless path.

3. In a process as set forth in claim 1 wherein the flexible retarder ismoved at a speed ratio of about 5 0:] 2? s t foiih iii claim 1 whereinthe flexible retarder is moved continuously during movement of saiddriving means.

5. In a process as set forth in claim 1 wherein the flexible retarder ismoved intermittently during movement of said driving means.

6. In a process of mechanically compacting a material of predeterminedthickness which comprises driving the material into an accumulationcavity having an inlet of a predetermined clearance greater than thepredetermined thickness of the material and an outlet of a predeterminedclearance less than the predetermined clearance of the inlet, and whilesimultaneously supporting the material on one side on a moving memberthroughout the accumulation cavity, frictionally engaging the materialon the opposite side with a surface of a flexible retarder throughoutthe accumulation cavity to impose a friction force thereon opposite tothe direction in which the material is driven for slowing the forwardmovement of the material to increase the thickness of the material andto accumulate and longitudinally compress the material within theaccumulation cavity as the material is driven through the cavity, andpreventing the accumulated material from backing up out of theaccumulation cavity; the step of moving the flexible retarder at a speedslower than the moving member during movement of the moving member topresent fresh surfaces of the flexible retarder to the web duringcompaction of the web.

UNITED STATES PATENT OFFICE Patent: No. Dated Inventor(s) Alexander L.Trifunovic et 8.1

It is certified that error appears in the above-identified patent andthat said Letters Patent are hereby corrected as shown below:

First printed page, under "Related U.S. Application Data."

"Division of Ser. No. 793,7o t" should be --Division of Column 2, line20, "or" should be --on-- Column 3, line 50, "a" should be --a.t-'-

Column 4, line 58, "22" Should be --27-- Signed and sealed this 9th ofJanuaryml973.

(SEAL) Attest:

EDWARD M.FIETCHER,JR. ROBERT GOTTSCHALK Attesting Officer CommissionerofPatents F ORM PO-1050(10--69) USCOMM'DC 60376-1 59 Q U S. GOVERNMENTPRINTING OFFICE: 5969 O35633

1. In a process for mechanically compacting a material of predeterminedthickness including the steps of driving a length of the material via adriving means while confining the material to maintain the predeterminedthickness and substantially undistorted state of the material,thereafter driving the length of material via said driving means into anaccumulation cavity having an inlet of a predetermined clearance greaterthan the predetermined thickness of the material and an outlet of apredetermined clearance less than the predetermined clearance of theinlet, and frictionally engaging the material being advanced through theaccumulation cavity on one side of the material with a surface of aflexible retarder throughout the accumuLation cavity to impose afriction force thereon in a direction substantially opposite to thedirection in which the material is advanced for slowing the forwardmovement of the material while simultaneously supporting the material onthe opposite side on the driving means throughout the accumulationcavity to increase the thickness of the material upon being advancedinto the cavity and to accumulate and compress the materiallongitudinally within the cavity as the material is advanced through thecavity; the step of moving the flexible retarder relative to the drivingmeans at a speed less than the speed of the driving means to presentfresh surfaces of said flexible retarder to the conveyed web duringmechanical compaction of the web.
 2. In a process as set forth in claim1 wherein the flexible retarder is moved through an endless path.
 3. Ina process as set forth in claim 1 wherein the flexible retarder is movedat a speed ratio of about 50:1 with respect to said driving means.
 4. Ina process as set forth in claim 1 wherein the flexible retarder is movedcontinuously during movement of said driving means.
 5. In a process asset forth in claim 1 wherein the flexible retarder is movedintermittently during movement of said driving means.
 6. In a process ofmechanically compacting a material of predetermined thickness whichcomprises driving the material into an accumulation cavity having aninlet of a predetermined clearance greater than the predeterminedthickness of the material and an outlet of a predetermined clearanceless than the predetermined clearance of the inlet, and whilesimultaneously supporting the material on one side on a moving memberthroughout the accumulation cavity, frictionally engaging the materialon the opposite side with a surface of a flexible retarder throughoutthe accumulation cavity to impose a friction force thereon opposite tothe direction in which the material is driven for slowing the forwardmovement of the material to increase the thickness of the material andto accumulate and longitudinally compress the material within theaccumulation cavity as the material is driven through the cavity, andpreventing the accumulated material from backing up out of theaccumulation cavity; the step of moving the flexible retarder at a speedslower than the moving member during movement of the moving member topresent fresh surfaces of the flexible retarder to the web duringcompaction of the web.